A Custom Equipment Support Project: From Design to Deployment

According to a recent study, over 70% of construction delays are attributed to inadequate planning and poor execution of any aspect of the project. For rooftop projects, this mostly happens due to lack of support structures for equipment and piping systems. This shows just how important a well-designed and properly installed equipment support system can really be.

At PHP Systems/Design, we pride ourselves on our ability to deliver custom support solutions tailored to the unique needs of each project. We are a custom rooftop support system manufacturer, be it for equipment, wires, crossovers, employee safety, or more.

Today, we shall take a closer look at the journey that a custom equipment support project usually goes through. We will focus on different aspects of the project, ranging from design to deployment, focusing on a specific case study: the Spring Branch ISD Admin Building.

The Foundation of a Good Equipment and Pipe Support Structure

A good equipment and pipe support structure must be robust, adaptable, and reliable. These structures are critical in maintaining the stability and functionality of essential building systems, such as HVAC, plumbing, and electrical systems. Key factors to consider in designing these support structures include:

• Load-Bearing Capacity: The structure must support the weight of the equipment and pipes, including dynamic loads from wind and seismic activity. For instance, here is a table showcasing the capacity of different materials commonly used in equipment and pipe support projects.

• Material Durability: Materials should be chosen based on environmental conditions, ensuring resistance to corrosion and wear.
• Flexibility: The design should accommodate future changes or expansions without significant modifications.
• Compliance with Standards: Adhering to local and international building codes and standards ensures safety and reliability.
• Vibration Isolation: Effective vibration isolation is crucial to prevent mechanical equipment vibrations from being transmitted to the building structure. Isolation pads or mounts can be used to reduce noise and prolong the lifespan of both the equipment and the building.
• Ease of Installation and Maintenance: The support structure should be designed for easy installation and maintenance. Modular components that can be quickly assembled or disassembled simplify the process and reduce labor costs.
• Thermal Expansion Accommodation: Pipes and equipment expand and contract with temperature changes. The support structure should accommodate this thermal movement to prevent stress and potential damage.
• Weather Resistance: Exposure to outdoor elements requires supports that can withstand harsh weather conditions, including UV radiation, rain, snow, and temperature fluctuations. Weather-resistant coatings and materials are essential for longevity.
• Aesthetic Integration: For buildings where visual impact is important, the support structures should integrate aesthetically with the overall design. This is particularly relevant in commercial or public buildings where rooftop equipment might be visible.
• Modularity and Scalability: Modular support systems allow for scalability and reconfiguration. This is beneficial for buildings that may need to upgrade or add more equipment in the future without a complete overhaul of the existing support structure.
• Cost Efficiency: While initial costs are important, it is crucial to consider the total cost of ownership, including maintenance and potential future modifications. Investing in high-quality, durable materials can reduce long-term costs.
• Safety Features: Incorporating safety features such as guardrails, anti-slip surfaces, and accessible walkways ensures the safety of maintenance personnel working on the rooftop.
• Load Distribution: Proper load distribution prevents point loading, which can damage the roof membrane. Distributed loads reduce stress on any single point, ensuring the roof’s integrity is maintained.

Case Study: Spring Branch ISD Admin Building

The Spring Branch ISD Admin Building in Houston, TX, required a rooftop support system to accommodate various equipment and piping needs. The project involved the installation of pipe supports, duct supports, equipment support systems, cable trays, and other system components.

Assessment Phase

The project began with a detailed site assessment. Our team conducted a thorough analysis of the building’s structural integrity and existing rooftop installations. We worked closely with the building’s management to understand their specific requirements and constraints. We also analyzed the day-to-day loads, geological factors, and more that the roof would experience. Our team also conducted an in-depth anomaly study for the region to ensure that the end-product was ready for anything.

The process involved three critical planning steps:

1. Site Assessment: Evaluating the rooftop’s structural capacity and environmental conditions.
2. Design Phase: Creating detailed design plans tailored to the building’s needs.
3. Material Selection: Choosing appropriate materials based on durability and load requirements.

Design and Customization Phase

During the design phase, we developed custom support solutions to meet the unique needs of the Spring Branch ISD Admin Building. This included designing supports for HVAC units, plumbing pipes, and electrical conduits.

The process involved our teams focusing on:

• Pipe Supports: Custom-designed to handle the building’s extensive plumbing network.
• Duct Supports: Modular supports that could be adjusted to accommodate future changes.
• Equipment Supports: Robust structures designed to support heavy HVAC units and other equipment.

One of the major challenges during the installation was the discovery of unexpected rooftop obstructions that were not accounted for in the initial plans. This required immediate adjustments to the duct support designs.

We encountered a series of vents and chimneys that were not in the original design plans. There was also a retaining wall that had several protrusions into the roof itself, drilling into which would impact the overall strength of the rooftop.

Our team decided on manufacturing bespoke support brackets that wouldn’t require any drilling into the rooftop and the pipe was structured such that it allowed the equipment to be installed around these obstructions without compromising stability.

Equipment Support Systems and Cable Trays

In addition to the pipe and duct supports, we were also tasked with providing equipment support systems and cable trays. These systems would ensure the safe and organized routing of electrical and communication cables.

The project was executed in several phases over the course of one month. These phases included:

1. Design and Customization: Detailed planning and design to meet specific project needs.
2. Material Procurement: Sourcing high-quality materials based on project requirements.
3. Installation: Efficient and precise installation, addressing any on-site challenges promptly.
4. Final Inspection: Thorough inspection to ensure all systems are properly installed and functioning as intended.

Final Inspection and Handover

Upon completion of the installation, a final inspection was conducted to ensure all systems were correctly installed and functioning as expected. The project was completed on time and within budget, thanks to the collaborative efforts of our team and the building’s management.

Our inspection checklist included several aspects, including:

• Verifying structural integrity of supports under load.
• Applying geographical loads on the supports to ensure viability.
• Ensuring all equipment is securely mounted.
• Checking alignment and stability of pipe and duct supports.
• Confirming cable trays are properly installed and cables are organized.

The Spring Branch ISD Admin Building project showcases the importance of detailed planning, custom design, and precise execution in delivering effective rooftop support systems.

At PHP Systems/Design, we take pride in our ability to address unique project challenges and deliver tailored solutions that meet the highest standards of quality and safety. To learn more about the project or to request pricing for your own project, call us at 800.797.6585. Our experts are always ready to help you out with your commercial roof equipment and pipe support project, no matter the complexity!